DUPONT™ CORIAN® SOLID SURFACE
PRODUCT FABRICATION BULLETIN
NA/ENGLISH
MICA AESTHETICS
INTRODUCTION
This bulletin summarizes the procedures for fabricating
DuPont™ Corian® solid surface containing mica flakes.
All typical fabrication and installation requirements,
seam reinforcement, for example, must be followed.
OVERVIEW
Corian® solid surface products with reflective mica flake
exhibit slight to moderate directionality. The degree of
directionality varies with mica sizes and concentrations.
Directionality is more apparent with smaller flakes at
higher concentrations where the mica flakes contribute
to the “background” appearance.
For best visual results, you will need to consider
directionality of the sheet, lighting type and locations
from where observers will view the sheet, the impact on
layout, and assembly techniques. This bulletin contains
several design ideas to get you started. With experience,
you will likely find additional techniques to maximize
the beauty and visual activity of your installations. Be
sure to show samples to your customer to ensure that
the design will meet their expectations.
Refer to the DuPont™ Corian® Solid Surface Product
Fabrication Bulletin – Directional Aesthetics (K-26833)
for a listing of colors that have some degree of
directionality and the appropriate Product Fabrication
Bulletin to follow.
The fabrication methods shown here often require
more sheet and fabrication effort than standard colors.
It is important to bid based on the sheet and effort
required, not on a square foot basis. The time to
discuss the various fabrication methods, their effects
on cost and appearance, and to set expectations is
BEFORE fabrication so the customer is not surprised
by the results. Physical samples can be helpful when
setting expectations.
This bulletin focuses on the unique characteristics of
these colors. The focus is on fabrication techniques that
are unique to these colors and assume an understanding
of Corian® fabrication. All typical fabrication and installation
requirements, seam reinforcement, for example, must be
followed. For complete details of assembly procedures, refer
to the DuPont™ Corian® Solid Surface Fabrication/Installation
Fundamentals bulletins. Illustrations shown here are not
completely representative of proper fabrication procedure. All
inside corners must be radiused. Reference DuPont™ Corian®
Solid Surface Fabrication/Installation Fundamentals –
Requirements (K-25705) for further details.
A. KEY DESIGN POINTS
This product is directional, both on the top surface and on the
edges. While changes in reflectivity at seams may be minimized
with the techniques shown here, it is generally not possible to
eliminate the visibility from all angles of observation.
The reflectivity of sheet edges significantly less than the face
of the sheet. If a uniform edge profile is required, a v-groove
edge is recommended.
The directional nature of the sheet must be accounted for
during design and fabrication. This directionality persists
through the thickness and is most apparent along the length
of the sheet. If two sections are joined with different
orientations so that they look different on the top surface, the
edge profiles may also look different.
Using the orientation of the product back side labeling as a
reference direction and marking all cut pieces with a
directional arrow will help later with properly orienting the
pieces during assembly. Otherwise, it may be difficult to
visually determine orientation of the cut pieces until they
are seamed together and the sample is finished.
All references to orientation in this bulletin will be relative to
the backside label on the sheet. When the sheet is oriented so
the text is upright, 0° will be LEFT, 90° will be UP, 180° will
be RIGHT and 270° will be DOWN. This terminology will
also be used to describe viewing angles. For an uncut sheet, to
view the 0° appearance is to stand at the 180° position and
look towards 0°. This is similar to how you would read a
compass, looking across the compass to look North.
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MICA AESTHETICS
Pick one piece, generally the largest one and use that as
your reference orientation. All other pieces can be oriented
relative to that piece. Picking 0° as the reference, the red
arrow indicates the reference orientation.
Visual Segment – A discrete section of the design that has
a uniform orientation and is intended to appear uniform.
It may consist of smaller segments with identical
orientations that are seamed with an inconspicuous seam.
90°
Reference Orientation
Observer Viewpoint – The position (depicted as an eyeball
in diagrams) and the angle (arrow in diagrams) from which
the design is viewed. Changing either the location of the
observer or the angle may change the appearance.
0°
180°
Back Label <<<<<<<<<<
C. VISUALIZING DESIGN
270°
Figure A-1 – Defining a Reference Orientation
It is important to remember that the visual effects are with
respect to the original sheet orientation, not to the seams
where sheets are brought together. The difference will be
delineated at the seams, but the angles where the effects
are most visible are dependent on the original sheet
orientations, lighting, and the position of the observer.
Lighting plays a strong part in the visibility of patterns.
Directional lighting can maximize visual effects when oriented
in a way that maximizes directional reflections. Uniform
area lighting may decrease the impact of the patterns.
The position of the observer is important. If the
installation will be primarily viewed from certain positions,
it is important to design so those positions have the
optimum appearance.
B. DEFINITIONS
Reference Orientation – A reference arrow or angle that is
the basis for defining all other orientations. For the
purposes of this document the sheet label (arrow drawing
towards beginning of label points at 0°) for the main
segment will be used and is shown by a red arrow in the
diagrams. For smaller designs where the design is an inlay
in a main sheet the backside labels are a good reference.
For larger or more complex designs other reference systems
may be appropriate.
Sheet Orientation/Segment Orientation – The angle of
sheets or segments of sheets relative to the Reference
Orientation. This is shown by black arrows in the figures
and defined in degrees, as in a compass.
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Using the arrows marking the sheet orientations is an
important concept in being able to visualize how a design
will look. A simple analogy is to imagine the arrows are
cars, with white headlights and red taillights. To
understand if two segments will be visually different
draw the design with the segment orientation arrows.
Using the car analogy, if the observer sees both arrows as
white (headlights) or red (taillights), then the visual
segments will have similar appearances. If one looks red
and the other white they will look different. It is
important to understand the position of the observer
viewpoint is critical, two different observers most likely
will see different visual appearances.
D. DESIGNING FOR DIRECTIONAL EFFECTS
At this time the products with mica aesthetics range from
having moderate to very little directionality. They are not
as well suited for designing directional effects as the solid
metallic colors. If directional effects are desired testing
with small mockups is recommended. Bold patterns with
larger areas are recommended. Refer to DuPont™ Corian®
Solid Surface Product Fabrication Bulletin – Metallic
Aesthetics (K-25703) for further guidance.
E. DESIGNING TO MINIMIZE DIRECTIONAL EFFECTS
The best way to achieve a uniform appearance is to
assemble all pieces with the same orientation. Where this is
unpractical, then the transition should look as natural as
possible, often achieved with a mitered seam.
When designing to minimize directional effects, the arrows
on the labels should be pointing so that they meet at some
point. The directional effect will be least visible from a
point midway between the two arrows, so the most likely
position that people will view the design must be
considered. This is shown in Figure E-1. The arrows are
representative of the sheet orientation as defined by the
sheet label in the backside product label. The eye and
arrow represent a viewer position and angle of observation.
DuPont™ Corian® Solid Surface Product Fabrication Bulletin
MICA AESTHETICS
Arrow Shows
Sheet Orientation
Eye Shows Angle
Pattern is Least Visibile
Best from
all angles
Correct
Avoid
Avoid
Avoid
Figure E-1 - Designing to Minimize Directional Effects
Note that even two sheets seamed together with the same
orientation may have a visible change in reflectivity at the
seam when observed from certain angles for colors with
stronger directional effects. For widths of less than two
sheets, visibility will be minimized by removing equal
amounts from each sheet along the inside of each sheet.
The seam will then be made at the freshly cut edges.
Incorrect
Figure F-1 - Diagonal Corner Seams
F.2. Offset-Seamed Corners
If one side of an “L” is less than 60 inches (152.4 cm)
then a typical off set seam can be used at the corner.
Additional 30 inch sections could be added, maintaining
the common orientation as shown in Figure F-2.
F. SEAMS
Light reflection varies as the mica colors are viewed from
different angles. This can appear as a color difference when
sheets are joined. Common examples of where sheets may
come together at 90° angles are “L” or “U” shaped tops.
This is a natural feature of the aesthetic and will be more
evident in some colors and finishes than others. It is best
to have samples to show the customer so it is understood
what the final piece will look like.
The sheet orientations should be as below on the left,
with the arrows in the backside label both pointing in
the same direction.
See DuPont™ Corian® Fabrication/Installation Fundamentals
– Positioning of Seams (K-25288) for more information.
F.1. Diagonally Seamed Corners
When two sheets need to be joined at an angle a diagonal
seam will provide the best appearance. A diagonal seam
will provide a subtle, neatly tailored change in
directionality. This seam will be least noticeable looking
down the diagonal and directly above. The seam is most
visible looking down the length of the sheets at low angles.
The sheet orientations should be as shown in the
“correct” example in Figure F-1, backside sheet labels
both pointing either towards the corner as in the diagram
or both arrows pointing away from the corner. They
should not meet in a head-to-tail orientation as shown in
the “incorrect” example in F-1.
DuPont™ Corian® Solid Surface Product Fabrication Bulletin
Correct
Incorrect
Figure F-2 - Offset Corner Seams
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MICA AESTHETICS
G. EDGE OR CORNER DETAILS
H. COVES
This section addresses options for corners or edges. The mica
aesthetic colors have reflective mica flakes that are generally
oriented in the plane of the sheet. Thus the edge of the sheet
shows the edges of the mica flakes. As the edges reflect less
light compared to the surface of the flake, the edges of the
sheet will have a darker, less reflective appearance.
For aesthetics with mica reflectivity varies with the
orientation of the mica flakes to the viewer. Creating the
cove reveals the interior of the sheet, and the mica flakes
will not be aligned with the surface cut of the cove.
Depending on the angle of observation, the cove may
match, but will tend to look darker than the horizontal or
vertical surfaces surrounding it at other angles. Coves are
therefore not recommended if the aesthetic has significant
reflectivity. If a cove is required, the v-groove technique
provides the best cove, but it will be visible from some
angles. Make sure the customer sees a sample and approves
the appearance. Set-on or butt-seamed back splashes are
recommended. See DuPont™ Corian® Fabrication/
Installation Fundamentals – Backsplashes (K-25294) for
more information.
If a drop edge is used, the surface reflectivity of the vertical
edge contrasts with the edge view of the top sheet.
Therefore a more suitable aesthetic is obtained using a
v-groove edge. A v-groove edge will give the most uniform
appearance when a tight radius is used. A small radius may
be used, but lack of reflectivity in the radius may be
noticeable above a 3/16" (5 mm) radius.
Figure G-1 - V-groove Edge
The appearance of a stacked edge does differ from the top
appearance and there will be relatively little reflectivity
on the edge. This is most apparent for a flat edge. The
stacked sheets should have the same orientation as the
top sheet. Different profiles (bullnose, ogee, etc.) will
give different effects.
Drop edges or a butt seam on a vertical corner are not
recommended unless the visual contrast is desired. In all
cases, having samples to show customers so they
understand the visual details will help avoid surprises when
the job is installed. An ogee or a bevel may create an
acceptable edge, though reflectivity will be lower and vary
with angle of observation. The ogee or bevel cut should
extend to the seam with the drop edge. This is deeper than
typical and will necessitate reinforcing the drop edge with
another strip of sheet (double thickness).
See DuPont™ Corian® Fabrication/Installation Fundamentals
– Edge Details and Buildups (K-25293) for more information.
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Figure H-1 - V-groove Cove
I. THERMOFORMING
DuPont™ Corian® solid surface with mica flake can be
thermoformed using typical settings. Thermoforming
behavior will be comparable to products similar in
coloration without mica flake. It is important to account
for directionality during the design of the part and during
fabrication. To track orientation it is best to put arrows on
each piece indicating the orientation relative to the
backside label. See DuPont™ Corian® Fabrication/
Installation Fundamentals – Thermoforming (K-25297) for
more information.
DuPont™ Corian® Solid Surface Product Fabrication Bulletin
DUPONT™ CORIAN® SOLID SURFACE
PRODUCT FABRICATION BULLETIN
MICA AESTHETICS
J. FINISHING
L. SUMMARY
All typical finishing methods are suitable to use on
Corian® colors containing mica. Darker colors may have a
better appearance with a semi-gloss finish. As with other
dark colors, the color will get darker and deeper with
higher gloss finishes. The mica flakes and directionality
effects will also be more apparent at higher glosses. The
consumer should be made aware of the proper care and
maintenance instructions for the provided gloss level. The
use of low angle lighting will help highlight scratches for
removal. It also may be necessary to finish up with a finer
than normal grit of abrasive. As always, cleaning the top
between grit changes is needed. The entire surface should
have a uniform finish, paying particular attention to
finishing after field seaming. See DuPont™ Corian®
Fabrication/Installation Fundamentals – Finishing and
Polishing (K-25298) for more information. For dark colors
DuPont™ Corian® Solid Surface Product Fabrication Bulletin
–Fabricating Dark Colors (K-27414) may also be useful.
The directional nature of mica flakes in these Corian® colors
allows for some creative designs that change with viewing
angle. When directionality is not desired many typical
fabrication techniques can be used, but an awareness of the
impact of sheet orientation on fabrication methods is
required to minimize the effect of directionality. In addition,
all requirements as set forth in Tech Bulletin, DuPont™
Corian® Solid Surface Fabrication/Installation Fundamentals
Requirements (K-25705) must be followed.
K. COLOR SPECIFIC COMMENTS
The strength of the directional effect depends on the size,
concentration and visibility of the mica. For products with
fairly strong mica aesthetic effects (e.g. Anthracite) the
directionality is most apparent at seams with changes in
sheet orientation, coves, stack edges and 90° butt seams (e.g.
drop edge). For products with more subtle mica aesthetic
effects (e.g. Deep Anthracite) the directionality less apparent
and may not be noticeable at seams with changes in sheet
orientation and coves. The lack of reflectivity on the edges of
the sheet is still readily apparent for stack edges and 90° butt
seams (e.g. drop edge). Physical samples are effective at
demonstrating the effects and determining if the end result
will be accepted by the customer.
M.REFERENCED DOCUMENTS
DuPont™ Corian® Fabrication/Installation Fundamentals –
Positioning of Seams (K-25288)
DuPont™ Corian® Fabrication/Installation Fundamentals –
Edge Details and Buildups (K-25293)
DuPont™ Corian® Fabrication/Installation Fundamentals –
Backsplashes (K-25294)
DuPont™ Corian® Fabrication/Installation Fundamentals –
Thermoforming (K-25297)
DuPont™ Corian® Fabrication/Installation Fundamentals –
Finishing and Polishing (K-25298)
DuPont™ Corian® Fabrication/Installation Fundamentals –
Requirements (K-25705)
DuPont™ Corian® Solid Surface Product Fabrication
Bulletin – Directional Aesthetics (K-26833)
DuPont™ Corian® Solid Surface Product Fabrication
Bulletin – Fabricating Dark Colors (K-27414)
Disclaimer:
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© E.I. du Pont de Nemours and Company 2013. All rights reserved.
The DuPont Oval, DuPont™ and Corian® are trademarks or registered trademarks of E.I. du Pont de Nemours and Company (“DuPont”) or its affiliates. K-27484 12/13
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